System and method for making composite material components

ABSTRACT

A system for making and using composite material components is disclosed. Composite material components are preferably constructed in patterns where every part needed for a given filler is included in a single series pattern. Using these series patterns, the material can be cut, folded and the parts created in a manner such that the individual parts forming a single filler are releasably attached to one another, thus resulting in effective and efficient organization of these parts. The filler panels can then be arranged into a folding stack of offset edges. Two shapes are preferably used with subtle differences between each at the fold area. Different patterns can be used to have the first two panels in the series positioned at 0 degrees, followed by two panels positioned at 45 degrees, and then alternating the angle positions throughout the pattern. The pattern preferably incorporates triangular portions or tabs between each set of panels in the series to help in establishing a fold line. These tabs forming part of the composite material component system are then discarded after the filler panels are created.

This application is a divisional of application Ser. No. 11/669,834,filed Jan. 31, 2007, status allowed.

TECHNICAL FIELD

This invention relates in general to the field of composite material andmore particularly, to a system and method making composite materialcomponents or assemblies. The invention is particularly useful for usein making composite components for the aerospace industry.

BACKGROUND OF THE INVENTION

The manufacture of composite material components generally require useof a large number of individual parts or panels, comprised of varioustypes, sizes, orientations and thicknesses of materials required tosupport the construction of various composite parts. Specifically, theaerospace industry requires a large number of panels (which may bereferred to in the aerospace industry as plies, and thus may be usedinterchangeably) to be used as filler materials, in order to construct asingle aircraft. These filler materials comprise a number of panelshaving a variety of shapes and sizes, but sometimes a large number ofpanels having similar size and shape are required. As an example,graduated sizes of nearly rectangular panels of filler materialsometimes need to be prepared such that many panels can be compactedtogether for use in construction of an aircraft. In order to obtain eachof these individual panels of filler material, each panel would have tobe cut individually from a fabric sheet. In an alternative manner ofdevelopment, panel parts having a similar size have been designed in aseries pattern to be cut together, but the panel parts would later haveto be separated using a cutting device.

When the number of panel fillers needed for construction reaches largequantities, the number of panels (or plies) required increases by asmuch as approximately tenfold. This increase in the number of panelsrequired sometimes results in a laminate build-up with bevels on allfour edges. The graduation of sizes produces the bevel shape, as thepart would not be trimmed after compaction. Some attempts have been tocompact large pieces of fabric into a laminate, corresponding to thenecessary filler thickness, and then the panel fillers would be cutusing a ply cutter, such as an AGFM 6 axis ply cutter. However, theappropriate tooling is not always available which makes this a lessviable option.

Alternatives to cutting each panel individually includes cuttingrectangles of material into individual panels of a certain size and thencompacting those rectangles to build a filler. Each panel is graduatedby a certain offset to be a different net size, so as the second panelwould be offset again from the net size of the first panel, and so forthuntil the number of panels (or plies) needed for the laminate wascomplete. With this method of preparing panels, given the volume ofpieces and the number of different types of panels needed, it presents achallenge to keep the panels organized so that the desired panels can beeasily identified and selected for use in the compacting process to forma filler. Having each panel separate requires marking and tracking eachpanel individually. Further, given that the panels would typically bestrewn across a compaction table, the panels would have to be collectedfrom the table to form a kit for later assembly and thus the laminatemay need to be created at the compaction table. This results in reducedflexibility in where and how these fillers are prepared for use in theconstruction process, particularly given that the pieces would have tobe stacked sequentially to meet requirements for proper assembly.

Other options for preparation of these fillers have included usingtab-out stringers; building ply blankets and then cutting out the panelsusing a cutter, such as an AGFM cutter; using a Gerber cutter; using atwo-step filler (filler and postage stamp); and using a one-step fillerplus shear tie shim. Use of tab-out stringers has shown not to bepreferable as there is significant material waste. When a ply blanket isbuilt, the AGFM knife must cut through several lengths of materialbearing the pattern at the same time and this is not an easy task toperform with an AGFM. When a traditional Gerber cutter is used, eachpanel must still be cut individually and each piece must be selectedindividually from the compaction table once cut. Further, the Gerbercutter only cuts a 90 degree cut. Thus, use of this method results in notime savings. Using a two-step filler process results in lay-upcomplexity (hand lay-up, automation issues, location tolerance),assembly complexity (shear-tie foot, probability of shimming), toolingcomplexity, and engineering complexity. Similarly, the one-step fillerplus shear tie shim process results in lay-up complexity (hand lay-up),automation issues (location tolerance), assembly complexity (shear-tiefoot, probability of shimming), tooling complexity, as well asengineering complexity.

These prior methods described above require time-consuming manualpreparation and organization of the panels to later be used in fillermaterials. When the same selection of panels are to be used over andover again, a problem results in that these panels are not beingorganized or stacked together initially, and thus, the user has tosearch for the appropriate panels each time a filler is to be prepared.As the number of small parts needed increases, the number of steps forcutting the small parts increases as well.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a system and method for preparingand organizing a large number of parts to be used together in amanufacturing process. These parts are prepared and organized using afolding process wherein the parts are formed as a connected kit. Oneembodiment is directed to a method for making a composite materialcomponent including the steps of providing a blank fabric sheet, forminga first panel in the fabric sheet, forming a second panel in the fabricsheet adjacent to and releasably separated from the first panel to forma first panel pair, forming a second panel pair adjacent to andreleasably separated from the first panel pair by a tab. The method maypreferably include forming the tab having two adjacent triangularportions releasably separated from one another. Additional panel pairsmay be formed in an embodiment of the method of the present invention,and each panel pair is preferably separated by tabs. Further embodimentsprovide for forming a postage stamp adjacent to and releasably separatedfrom one of the panel pairs by a tab, and additionally or alternativelyforming the postage stamp at the end of the fabric sheet.

In a further embodiment, a composite material component system isdisclosed comprising at least two panels releasably attached by a foldline to form a panel pair, and plural panel pairs releasably attached bya tab. The tab may preferably have two adjacent triangular portionsreleasably separated from one another. The system may further include apostage stamp releasably separated from a panel by a tab. This postagestamp may preferably be releasably separated from a panel by a tabhaving two adjacent triangular portions releasably separated from oneanother. Additionally or alternatively, the postage stamp may bereleasably separated from a panel by a tab at the end of the fabricsheet.

In another embodiment, a composite material component preferably formedby the method disclosed in the present invention may preferably befolded allowing for use of individual component parts by folding thefirst panel of the first panel pair that is marked over the adjacentpanel of the first panel pair, folding tab outside the folded firstpanel pair, folding the next panel adjacent to the tab underneath thefolded first panel pair, and folding remaining panels and tabs intostacks until the final panel in the composite material component isreached. The tabs are then separated from the stack of panels.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIG. 1 depicts a fold-up according to an embodiment of the presentinvention;

FIG. 2 depicts a fold-up according to an embodiment of the presentinvention;

FIG. 3 depicts an embodiment of a fold-up wherein the fold-up has beenfolded according to an embodiment of the present invention and thetriangular portion has not been removed;

FIG. 4 depicts an embodiment of the present invention wherein thetriangular portion included initially in the fold-up has been removed;

FIG. 5A depicts two panels of a fold-up according to an embodiment ofthe present invention wherein a straight line cut is incorporated;

FIG. 5B depicts the two panels shown in FIG. 5A when folded on top ofone another;

FIG. 6A depicts two panels of a fold-up according to an embodiment ofthe present invention wherein a curved or angled line cut isincorporated;

FIG. 6B depicts the two panels shown in FIG. 6A when folded on top ofone another;

FIG. 7 depicts an embodiment of the fold-up according to the presentinvention where a series of curved cut panels are used;

FIG. 8 depicts a pattern for a series of fold-ups of varying shapes andsizes according to the present invention; and

FIG. 9 is a flow chart depicting a method for forming a compositematerial component system according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

According to embodiments of the present invention, filler patterns canbe constructed wherein every part needed for a given filler is includedin a single series pattern. Using these series patterns, the materialcan be cut, folded and the parts created in a manner such that theindividual parts forming a single filler are releasably attached to oneanother, thus resulting in effective and efficient organization of theseparts as will be described in detail below. The filler panels can thenbe arranged into a folding stack of offset edges. Two shapes arepreferably used with subtle differences between each at the fold area.Different patterns can be used to have the first two panels in theseries positioned at 0 degrees, followed by two panels positioned at 45degrees, and then alternating the angle positions throughout thepattern. The pattern preferably incorporates a triangular portionbetween each set of panels in the series to help in establishing a foldline. The cut line is not a straight line in that it curves back so thatwhen a fold is made, there is overlap in folding. The triangular portionis then discarded after the filler panels are created by cutting ortearing if possible. It should be appreciated that when a 0 degree angleis referenced, it is equivalent to a 90 degree angle, and similarly, a−45 degree and a 45 degree angle are equivalent. The tolerance for thesefiber angles is about the range of 3-5 degrees.

FIG. 1 depicts fold-up 10 according to an embodiment of the presentinvention. Fold-up 10 is comprised of a series of panels (or componentparts) positioned at different angles and, in some instances, havingvarying shapes. Panels 101 and 103 are divided by fold line 111. Foldline 111 is releasably attaching panels 101, 103 such that when thefolding method contemplated by the present invention is completed,panels 101, 103 can be separated from one another, either manually or byother means, without necessarily requiring more involved separationtechniques (i.e., use of a cutter). Panels 101, 103 are viewed to bevirtually minor images of one another such that when these adjacentpanels are folded on top of one another, panels 101, 103 will berelatively flush with one another, although to some degree, one paneltypically may protrude beyond the edge of another panel (in a stair-steptype manner) without departing from the objects or spirit of the presentinvention.

Panel 103 is separated from panel 105 by triangular portion 104.Triangular portion 104 is formed to be two triangle shapes mergedtogether and positioned such that when fold-up 10 is folded beginning atpanel 101, triangular portion 104 serves to change the angle ofpositioning, thus establishing the fold line when panels 105 and 106 arethen folded. Pieces, such as triangular portion 104, are included afterevery two panels in fold-up 10; however, it should be appreciated thatin alternative embodiments of the present invention, triangular portion104 may be included more or less often than after every two panelswithout departing from the objects of the present invention.

Further, it should be appreciated that the panels in which triangularportion 104 precedes do not have to be the same size and shape. As anexample, panel 107 is of a different size and shape than panel 112;however, triangular portion 113 precedes panel 112. In this instance,panel 107 is included as part of the fold-up when a larger sized partmay be desirable and further, panel 107 serves to change thedirectionality of fold-up 10 at the tail-end of the folding process.

Fold-up 10 includes postage stamp pieces. These postage stamps are smallpieces used within the industry to equalize areas where a filler willconnect between two parts (such as stringers) of unequal thickness at agiven location. There can be as many as five postage stamp pieces on theend of a typical fold-up, although only three postage stamps 108, 110,114 are depicted in FIG. 1. Postage stamps may preferably beincorporated into a fold-up in a variety of different embodiments. Inone embodiment, the last filler panels of the fold-up are extended longenough to include the postage stamp. In another embodiment, the postagestamp pieces are folded out from the last panel. In this manner, thepostage stamp folds into the filler panel and can then be extended toallow for any shape desired and for as many postage stamps as areneeded. Regardless how the postage stamps are incorporated, only onepiece of material is preferably needed in order to handle any one fillerto be created.

Panels 101, 103 are positioned at a 90 degree angle while panels 105,106 are positioned at a 45 degree angle. It follows that the next pairof panels following panels 105, 106 are positioned at a 90 degree anglesimilar to panels 101, 103. By alternating the angle at which sets ofpanels are positioned, the method of folding contemplated by the presentinvention may be more easily achieved so as to change the direction ofthe fold line and thus allowing triangular portions 104, 109 to beseparated from the panels in the folding process. It should beappreciated however that angles of positioning other than 90 degrees and45 degrees may preferably be used without departing from the objects ofthe present invention.

FIG. 2 depicts another embodiment of the present invention. Fold-up 20includes a series of panels with triangular portions interspersedbetween sets within the series of panels. Panels 201, 203 are separatedby fold line 205 wherein, similar to what has been previously describedwith respect to FIG. 1, fold line 205 releasably attaches panels 201,203 such that when the folding process is completed, panels 201, 203 canbe separated from one another. Also, similar to the embodiment depictedin FIG. 1, panels 201, 203 are positioned at a 90 degree angle while thepanels following triangular portion 204 are positioned at a 45 degreeangle.

The presence of marking 202 incorporated into panel 201 should be noted.Marking 202 is present for a variety of reasons but generally to providethe user with an indication as to identifying the panel within fold-up20 where the folding process should begin. The folding method is setforth in FIG. 9. The user will preferably pick up fold-up 20 (step 905of FIG. 9) and starting with panel (or ply) 201, will fold this panelsuch that it is placed on top of panel 203 (steps 906 and 907 of FIG.9). The fold-up process occurs until all panels are folded on top of oneanother and the respective triangular portions are to the side of thepanels, though still attached to the panels (steps 908-910 of FIG. 9).When all of the panels have been folded, marking 202 will be visible onpanel 201, as this panel preferably will be on the top of the panelstack (step 912 of FIG. 9). While marking 202 is depicted in FIG. 2 ashaving a series of numbers, it should be appreciated that any lettering,numbering or inclusion of symbols or other types of markings that isdesired by the user may be incorporated on the panel or piece withoutdeparting from the objects of the present invention. Regardless whattype of identifier is used for the marking, the marking provides anidentifier for the stack of panels once folded, such that each panel inthe stack does not have to be individually marked. Thus, marking 202preferably serves as the designation for the entire stack of pieces.This is a benefit of the present invention in that once the panels havebeen folded, all of the panels are still connected, but marking 202 maypreferably still be used as a double-check to ensure that the correctpanels are included in the stack, the right number of panels areincluded, and as they are all connected, the user does not have tosearch for the appropriate panels when the time arrives for thoseselected panels within the stack to be utilized.

Marking 202 includes numbers on the top panel, and these numbers mayindicate the number of thicknesses (i.e., the number of panels includedin the stack) and/or the particular part number where the panels are tobe applied among other identifiers that may be relevant to the stack ofpanels. The stack is arranged such that marking 202 is visible and canbe used as a guide for placement when it is properly oriented. Marking202 is used for assistance to start the folding process and organize theindividual panels forming the stack; otherwise, one would have to labeleach panel individually. As such, marking time is reduced by as much as90 percent on average. Marking 202 also is used as a check to know howmany panels are included as part of the filler.

Fold-up 20 depicted in FIG. 2 is slightly different in pattern whencompared to fold-up 10 of FIG. 1 in that fold-up 20 does not incorporatepostage stamp pieces. Sometimes these postage stamp pieces are notrequired for preparation of a particular filler, for example, and thus,the pattern of fold-up 20 is made without inclusion of such postagestamp pieces. However, it should be noted that panels 207, 208 have beenincorporated into fold-up 20, having slightly different shapes whencompared to panels 201, 203. When all of the panels forming fold-up 20have been folded in accordance with the process contemplated by thepresent invention, the panels preferably lay on top of one another in astair-step type pattern.

The patterns for the fold-ups depicted in FIGS. 1 and 2 are preferablycreated using computer modeling software wherein the points are manuallygathered on the periphery. Those points are then loaded into anexecutable program to create a file wherein the points are pulled offthe corners of the solid material being modeled. The points arescattered to the format of a fold-up, and the surface and boundarypoints for the fold-up are compiled into a file to be preferably loadedinto a software program, such as Autocad. It should be appreciated that,for some fillers that are more unique in design, the user may have tofirst manually offset for additional panels prior to exporting the plygeometry to a software program, such as Autocad. The pattern(s) may thenpreferably be projected onto the material for cutting using a plycutter. The type of ply cutter used to cut the pattern is not criticalto the invention as various ply cutters have been used to createpatterns for fold-ups, including Gerber ply cutters and AGFMs, althoughsome ply cutters may be less desirable to use because of the timerequired to operate.

Fold-ups such as those depicted in FIGS. 1 and 2 are folded to result inthe appropriate thickness and panel (ply) types needed for a particularfiller by designing the desired pattern on a blank fabric sheet (step901 of FIG. 9) and laying this design on the desired filler material(steps 902-904 of FIG. 9). The cut pattern is then removed from thedesired filler material. The panel containing markings (see FIG. 2,marking 202) is held (step 905 of FIG. 9) and the panel adjacent to themarked panel is folded underneath (steps 906-907 of FIG. 9). Thetriangular portion is folded outside of the folded panels in order toallow for change in the fold direction (step 908 of FIG. 9). The nextpanel adjacent to the triangular portion is folded under (step 909 ofFIG. 9), and the process of folding the panels together and thetriangular portions separate from the panels is continued until thefinal panel is reached (step 910 of FIG. 9). After all of the panelshave been folded into a stack (see FIG. 3), the triangular portions areseparated from the stack of panels (see FIG. 4 and step 911 of FIG. 9).The stack is then placed to the side with the panel containing themarkings on top, such that the markings identifying the stack arevisible (step 912 of FIG. 9). Orienting the markings in this manner isimportant so that the panel stack may be identified even aftercompaction has occurred.

In order to cut the panels (such as half-inch wide strips of material),the strips remain connected by cutting all but approximately the last0.050 of each end. In this respect, all the panels of a roll-up arestill connected and can be rolled up for ease of handling. Then theuncut tab can be slit or torn apart in order to separate the panels whenthe time arrives for the stack to be separated into individual panels.Similarly, for postage stamp pieces, multiple postage stamp pieces canbe cut together in one pattern (see FIG. 1). When two or more postagestamp pieces are needed, they can be prepared in series and then folded.These postage stamp pieces can be interwoven with those cut at 45degrees to maintain fold orientation as needed (i.e., alternating theplies of 0 and 45 degree orientation as shown in FIG. 1).

FIG. 3 depicts an embodiment of the present invention showing whatfold-up 20 preferably looks like when the panels have been folded butbefore separation of the triangular portions has occurred. Marking 304is shown as being on top panel 305 of the stack of panels 30 and thusvisible to the user to determine what types and number of panels shouldbe included in the stack. Triangular portions 301 are shown as not beingpart of the stack of panels 30; however, triangular portions 301 arestill releasably attached to the stack of panels at corners 302, 307.When the user is preparing to utilize panel stack 30, that user willseparate triangular portions 301 from stack 30 by pulling or tearingtriangular portions 301 apart from stack 30 at corners 302, 307. Also asshown in FIG. 3, stack 30 includes a variety of panels in addition totop panel 305 wherein these panels are folded to form stack 30. Thepanels are not all of the same size and thus some of the panels protrudefrom below top panel 305, such as panels 303, 306, forming a stair-steppattern. It should be appreciated that the stair-step pattern will laterdisappear and the edges will become smooth once the stack has beencured.

Turning to FIG. 4, there is depicted what fold-up 20 (FIG. 2) looks likewhen the triangular portions have been detached from the stack ofpanels. Similar to that depicted in FIG. 3, stack 40 includes top panel405 having marking 404 to confirm the number and type of panels includedin stack 40. Corners 402, 406 that were previously attaching thetriangular portions that were part of the initial fold-up to stack 40are still present as part of stack 40; however, now they are serving toreleasably attach the panels comprising stack 40 to one another. Again,the stair-stepping pattern of the panels 401, 403 comprising stack 40 isdepicted in FIG. 4.

FIGS. 5A and 5B represent before-and-after depictions of a pair ofpanels wherein a straight fold line has been employed. FIG. 5A depictspair 50 wherein panels 501, 502 have not yet been folded. Fold line 503is a straight line dividing cut, and also shown in FIG. 5A is protrusion504 demonstrating that panels 501, 502 are not perfectly symmetricalsuch that the panels will lie as stair-steps on top of one another whenfolded. Turning to FIG. 5B, there is represented a pair 50 once panels501, 502 have been folded. Having fold line 503 be a straight linedividing cut produces panel edges that are directly above one another.While panel 502 protrudes slightly from underneath panel 501, paneledges 505, 506 are directly above one another.

While a straight line dividing cut has been employed in connecting pair50 depicted in FIGS. 5A and 5B, it should be appreciated that otherdividing cuts may be employed without departing from the object andspirit of the present invention. In another embodiment, depicted inFIGS. 6A and 6B, a curved fold line has been utilized. Similar to FIG.5A, FIG. 6A depicts pair 60 wherein panels 601, 602 have not yet beenfolded. Fold line 603 is a curved line cut, and also shown in FIG. 6A isprotrusion 604 demonstrating that panels 601, 602 are not perfectlysymmetrical and thus lie in stair-step formation when folded. Turning toFIG. 6B, there is represented a pair 60 once panels 601, 602 have beenfolded on top of one another. Having fold line 603 be a curved cutproduces a staggered edge for subsequent panels. Thus, as shown in FIG.6B, panel edge 606 of panel 602 protrudes in a staggered manner withrespect to panel 601; however, edges 602, 605 are essentially aligned.

Turning to FIG. 7, an embodiment of a fold-up contemplated by thepresent invention is depicted wherein fold-up 70 is formed using aseries of panels 701, 702, 705 having curved edges on the sides of thepanels. While a circular pattern, such as that depicted in FIG. 7, ismore challenging to use in order to arrange a tight pattern with goodmaterial utilization, the curved edges still allow for folding inaccordance with the present invention. Having these curved edges meansthat instead of having triangular portions separating the panels, thepanels are preferably connected via these curved lines or curvatures. Asan example, curvature 704 separates panels 702,705 having triangularportions at the far ends of the panel connections. Thus, panels 702, 705are connected at a point midway down the panel as compared to beingconnected using the far corners as has been depicted in FIGS. 1 and 2.However, panels 701, 702 are separated by curvature 703 wherein panels701, 702 are still connected at the end points of the panels but theseparation part is more circular than triangular.

FIG. 8 depicts a series 80 of twenty panel patterns wherein theindividual panel patterns are labeled 801-820. Panel patterns includedin FIG. 8 include those having four different variants: (1) patternshaving 0 degree positioning without the inclusion of postage stamppieces; (2) patterns having 0 degree positioning and including postagestamp pieces; (3) patterns having 45 degree positioning without theinclusion of postage stamp pieces; and (4) patterns having 45 degreepositioning and including postage stamp pieces. Patterns included inseries 80 vary from 2-16 panels in size. Utilizing series 80, each ofthe different panel patterns can be designed to maximize the use of thematerial for making these panels by including all of these patterns onthe same piece of material. It should be appreciated that depending onthe cutting equipment being utilized and the dimensions of the material,fewer or more panel patterns could be included on the same piece ofmaterial without departing from the objects of the present invention.Some of the patterns include all 0 degree positioning (804, 805, 820,801, 802, 803, 819) while the other patterns in FIG. 8 include both 0degree and 45 degree positioning.

While embodiments of the method of preparing and organizing partsdisclosed in conformance with this invention are useful for most shapesand sizes of panels and postage stamps, it should be appreciated thatsome filler parts are unique and may not be easily prepared using themethod of the present invention.

Fold-ups contemplated by the present invention are prepared from amaterial that is flexible so as to permit folding yet the material ispreferably somewhat rigid so as to reduce the likelihood of prematuretearing during the folding process. Another characteristic of thematerial is that when the triangular portions are to be removed from thefold-up, these triangular portions can be removed manually as comparedto requiring a cutting apparatus. Preferable materials for use inpreparing fold-ups according to embodiments of the present inventioninclude fiberglass, composite carbon, Kevlar, graphite and other carbonfiber woven materials. It should be appreciated that these materialsalso may be coated with a resin (epoxy, for example) to make a pre-preg,using commercially available processes, as is common in the aerospaceindustry. Pre-preg is typically prepared by dipping collections offibers into a resin bath and then wringing out the material. Pre-preg istypically packaged with a protective cover sheet or backing materialapplied to protect it from contamination. The process of cutting may beperformed with or without the backing material, but the backing materialkeeps the material from sticking to itself. As long as the materialutilized is forgiving in that it can bend and compress, then it may beused in accordance with the method of the present invention.

The method contemplated by the present invention preferably eliminatesmore than one-half of the individual parts needed to be produced for anygiven filler. The volume of parts required will still be produced andinstalled but as a connected kit rather than as separate parts. Use ofthe method contemplated by the present invention further reduces theamount of time needed to produce the individual parts forming the fillerin that the method eliminates the need to have each and every panelindividually identified, handled several times, and then sorted severaltimes, and further, this method reduces the concern about losing ordamaging individual pieces. This is an improvement in time savingsbecause it is desirable not to have to cut out each individual panel,and thus, while it should be appreciated that in some instances morematerial may be utilized to form the panels, the time savings in nothaving to prepare each panel individually and/or locate each panel whenneeded preferably outweigh the costs of the material.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

1. A composite material component system comprising: a first panel and a second panel releasably attached by a fold line to form a first panel pair; and a third panel and a fourth panel releasably attached by a fold line to form a second panel pair, the first panel pair and the second panel pair releasably attached by a tab, the tab having two adjacent triangular portions releasably separated from one another, and wherein the first panel pair and the second panel pair are folded and stacked in a stair step configuration.
 2. The composite material component system of claim 1 further comprising: a postage stamp releasably separated from a panel by a tab.
 3. The composite material component system of claim 1 further comprising: a postage stamp releasably separated from a panel by a tab having two adjacent triangular portions releasably separated from one another.
 4. The composite material component system of claim 1 further comprising: a postage stamp releasably separated from a panel by a tab at the end of said composite material component system.
 5. The composite material component system of claim 1 further comprising: additional panel pairs, each panel pair separated by tabs.
 6. The composite material component system of claim 1 wherein the second panel pair is oriented at about a 45 degree angle from the first panel pair.
 7. The composite material component system of claim 1, wherein an upper panel in the stair step configuration comprises an identifying marking.
 8. The composite material component system of claim 1, wherein the first panel and the second panel are releasably attached at corner portions of the first panel and the second panel.
 9. The composite material component system of claim 8, wherein the first panel and the second panel are releasably attached at corner portions of the first panel and the second panel such that the first panel may be manually separated from the second panel.
 10. A composite material component system formed by steps comprising: forming a first panel pair by releasably attaching a first panel and a second panel in a fabric sheet by a first fold line; forming a second panel pair in the fabric sheet by releasably attaching a second panel and a third panel by a second fold line; and releasably attaching the first panel pair and the second panel pair by a tab, the tab having two adjacent triangular portions releasably separated from one another, wherein the panels are folded and stacked such that a number of edges of each panel form a stair step configuration.
 11. The composite material component system formed by the steps of claim 10, said steps further comprising: incorporating a postage stamp releasably separated from a panel of a panel pair by a tab having two adjacent triangular portions releasably separated from one another.
 12. The composite material component system formed by the steps of claim 10, said steps further comprising: releasably attaching a postage stamp to one panel by a tab at the end of said composite material component system.
 13. The composite material component system of claim 10, wherein an upper panel in the stair step configuration comprises an identifying marking.
 14. A composite material component, comprising: a fabric sheet having a first panel and a second panel, the second panel being releasably attached to the first panel by a first fold line to form a first panel pair; a second panel pair in the fabric sheet adjacent to and releasably separated from the first panel pair by a tab, the second panel pair comprising a third panel and a fourth panel releasably attached by a second fold line; and additional panel pairs in the fabric sheet, each additional panel pair releasably separated from an adjacent panel pair by a tab, wherein the panels in the component are folded and stacked such that a number of edges of each panel form a stair step configuration.
 15. The composite material of clam 14, wherein the first and second panels have straight side edges, and wherein the tab is of triangular shape.
 16. The composite material of claim 14, wherein the first and second panels have curved side edges, and wherein the tab is of a curved shape.
 17. The composite material component of claim 14, wherein an upper panel in the stair step configuration comprises an identifying marking. 